ZUKIWORLD Online | Suzuki 4x4 Editorial and Forum
ZUKIWORLD Discussion Forum => Suzuki 4x4 Forum => Topic started by: ebewley on November 04, 2010, 06:01:55 AM
-
Mike Hagen is at it again. He has just completed the first stage of Project ZR3. His goals were to have no aftermarket parts added at the completion of the first stage and to use what Suzuki already had available, just massaged and changed a bit in configuration. He has created quite a nice off-road all purpose vehicle and just like Mike he has already decided on a few more upgrades and modifications to be done in the near future. He's going to put a locker in the XL7 rear-end and the front is going to get a second frame chop between the rear of the front control arms and front diff raise.
Minneapolis, MN - Last Year I bought a 2001 Chevrolet Tracker from the classifieds right here on ZW. It was rough and I knew it, but it ran and drove, so it had to be worth $800 right? A couple hundred miles later the motor let go in a big way. I was bummed at first but after I got over my flawed investment I decided to turn a lemon into lemonade. It has always frustrated me that Chevrolet / Suzuki had all the key components to putting a great off-road package together for the Tracker/Vitara but never did. The closest they ever came was the ZR2 which, in my opinion, fell way short. I would have built a 2 door with, a V6, steel front diff, the much larger XL7 rear diff, XL7 brakes, 5.12 gear ratio and 33 inch tire. I decided to do just that. This is where the Project ZR3 begins.
http://www.zukiworld.com/month_110110/feature_project-zr3-the-way-a-tracker-should-have-been-built.htm (http://www.zukiworld.com/month_110110/feature_project-zr3-the-way-a-tracker-should-have-been-built.htm)
-
I like the build Hagen. Just as I was starting to lean to a 4door you have me thinking about frame chopping......
Kudos on the road trip. That is impressive, not only the stablity of the rig, but the fact you fit a family of four in it. Those newer models most have more room. ;) No way would I have fit all my luggage.
-
nice build!
Could someone tell me about the left car on the pic? Is there any info? ;)
(http://www.zukiworld.com/month_110110/images/project-zr3/23ZR3.jpg)
-
Thats Zukipilots newer rig. Liberty-Overland built it, there are some threads and I know this article too:
http://www.zukiworld.com/month_020109/feature_suzuki-sidekick-build-up.htm (http://www.zukiworld.com/month_020109/feature_suzuki-sidekick-build-up.htm)
-
BRD HNTR has been looking at the frame drop for a while now. Now we will really have to look into it. :)
-
With the first generation trackers and sidekicks aging I think the second generations are gonna become more popular. I almost bought a rough 01 2 door soft top locally. I REALLY like the all Suzuki all parts bin idea. Its too bad THEY didnt build this for the market.
-
-
Mike, You are One Heck of a Guy!
These Quick Builds that put Out Great Rigs... Amazing!
Very Nice...
And yeah, Let me guess, You're gonna be in the Ultimate Adventure with the Sleeper???
Win One for the Suzukis!!!
-
Just $3,100 into it, eh? Well I'll give you $3,500 now. Hey, it's $400 profit!
Okay, fine, $4,000?
:P
Great build. It looks great, and with all that upgraded drivetrain it sounds like it will hold up nicely. Mike has a tendency to beat up on his toys, so I've heard...so I'm sure it's been well-thought out to hold up to normal abuse
-
Kudos on the road trip. That is impressive, not only the stablity of the rig, but the fact you fit a family of four in it. Those newer models most have more room. ;) No way would I have fit all my luggage.
While I do believe that the newer body style is a tad larger I have done the same trip 3 times before in my first gen.
Its all about the packing. You can fit 3 of the mid size luggage (the largest you can use for carry on) behind the back seat in both first and second gen tracker. Extra shoes, pillows and stuff will also fit between the seat and luggage. On this trip I actually had put a middle seatbelt in from the GV and hauled my niece home from Florida. So it was actually 5 of us for 2500 miles. ;) We stopped at the post office and mailed one of our suitcases home so we could fit her luggage. I do the same thing on my motorcycle trips.
-
Once again Mr. Hagen manages to surprise us with another quality, quick-build. He does these things like my kids do Legos- quickly and well. Just more to stuff to show my Tracker and let it dream about... :sleepy: :)
-
That's awesome, I love it! Very creative on the frame chop and rear suspension. I have the same truck only in black and that certainly tempts me to build it up a bit.
-
Great job Mike.... A very impressive rig once again.... Even more impresive seeing it in person 8) See ya this spring, if not earlier.
Zig
-
Mike,
Do you have any more pix of the frame chop/drop? I'd like to see some plating pix before paint. Anything would be great. Thanks! (GREAT build by the way!)
Eric
-
I had a major engine problem with my little 99 yacker. The head gasket blew & I was wanting to attempt putting a v6 into mine. Everyone told me not to do it, cause it would cost too much money. I really wish that I would've done it instead of redoing the head gasket. My little yacker has the coils in it from a v6 model grand v. Since putting those coils in I've been able to put 235's under my baby but the ride is now compromised with the bigger springs. It rides rougher but sure does look better.
Love how yours turned out Mike. Gets me thinking about doing mine. I love all the ideas everyone has onthis site.
Thanks,
Jason
-
Mike,
Do you have any more pix of the frame chop/drop? I'd like to see some plating pix before paint. Anything would be great. Thanks! (GREAT build by the way!)
Eric
I do have some better pics but not on this computer. I wont be able to post them till tomorrow night.
-
BTW, Thanks for all the compliments. This was a much larger project than I had anticipated and Its always nice to see that others understand why I put forth the effort.
-
With a 4 1/2" frame chop & drop and sliding it forward, are you going to do a centered diff? At least your motor fits under the hood without modification.
You have done an amazing build in a short time, which shows the importance of having the entire donor vehicle for parts. Of course having a plan on what your are going to do helps (not to mention your skills).
-
I do have some better pics but not on this computer. I wont be able to post them till tomorrow night.
Excellent!
8)
-
Pic as requested. I used 3 inch strap but if I were to do it again I would have used a plasma cutter to cut a single piece of plate for each side. It is capped top and bottom. It was what I had and I was on a time constraint.
-
With a 4 1/2" frame chop & drop and sliding it forward, are you going to do a centered diff? At least your motor fits under the hood without modification.
I do not have plans to center mount this diff but I wont rule it out sometime in the future. I do like that mod.
-
I love the frame lift, great mod, I've wanted to do one to mine for about 5
years now, but I never have had a shop to work in :( .
What I just can't get over is how much rust is on the undercarriage after
only 10 years :o I don't know how you guys deal with it, I'm sure glad
I don't have to deal with that here.
Wild
-
I love the frame lift, great mod, I've wanted to do one to mine for about 5
years now, but I never have had a shop to work in :( .
What I just can't get over is how much rust is on the undercarriage after
only 10 years :o I don't know how you guys deal with it, I'm sure glad
I don't have to deal with that here.
Wild
LOL! I bought this rig because of how little rust it had! :o Thats no joke. Most of these dont even have any rockers left. First gen trackers have suffered a far worse fate around here. Most every first gen around here is near see through.
-
do you find you have much bump steer with the 33's on the rack and pinion steering?, that was my biggest issue when i had 33's on the xl7.
nice work btw, what are you going to do about the xl7 rear end locker issue?
-Lance
-
do you find you have much bump steer with the 33's on the rack and pinion steering?, that was my biggest issue when i had 33's on the xl7.
nice work btw, what are you going to do about the xl7 rear end locker issue?
-Lance
There is no bump steer. Keep in mind there really is no angle on the tierods. The front suspension is entirely stock. No lift at all. The wheels are stock and have the correct offset for the vehicle. I am not running a swaybar though so I do get a little body roll. I am going to try to swap V6 coils into the front and see if that helps. I havent been able to find any yet. I dont like running sway bars on off road rigs.
As for the XL7 locker issue, well, I dont know yet. I dont even know what the spider gears look like. :-X However, I have 31 spline ford spiders mixed with a suzuki lock rite locker in a tracker rear being used as a front diff in my buggy. After all that I would think the XL7 issue should be fairly simple. Just gotta figure out how much crap needs to be machined ;)
-
do you find you have much bump steer with the 33's on the rack and pinion steering?, that was my biggest issue when i had 33's on the xl7.
nice work btw, what are you going to do about the xl7 rear end locker issue?
-Lance
There is no bump steer. Keep in mind there really is no angle on the tierods. The front suspension is entirely stock. No lift at all. The wheels are stock and have the correct offset for the vehicle. I am not running a swaybar though so I do get a little body roll. I am going to try to swap V6 coils into the front and see if that helps. I havent been able to find any yet. I dont like running sway bars on off road rigs.
As for the XL7 locker issue, well, I dont know yet. I dont even know what the spider gears look like. :-X However, I have 31 spline ford spiders mixed with a suzuki lock rite locker in a tracker rear being used as a front diff in my buggy. After all that I would think the XL7 issue should be fairly simple. Just gotta figure out how much crap needs to be machined ;)
mmmmmm...
I would love to hear about it when you figure out a locker for the XL-7. Are all XL-7 diffs the same? I mean I have a 2006 set of axles - would the 4.25 gears swap for 5.12 from an older XL-7?
-
mmmmmm...
I would love to hear about it when you figure out a locker for the XL-7. Are all XL-7 diffs the same? I mean I have a 2006 set of axles - would the 4.25 gears swap for 5.12 from an older XL-7?
I am not 100% sure but I am under the assumption that they do.
-
mmmmmm...
I would love to hear about it when you figure out a locker for the XL-7. Are all XL-7 diffs the same? I mean I have a 2006 set of axles - would the 4.25 gears swap for 5.12 from an older XL-7?
I am not 100% sure but I am under the assumption that they do.
Thanks Mike. I guess I'll have to look into it some more.
-
However, I have 31 spline ford spiders mixed with a suzuki lock rite locker in a tracker rear being used as a front diff in my buggy. After all that I would think the XL7 issue should be fairly simple. Just gotta figure out how much crap needs to be machined ;)
I don't remember reading about running Ford spiders in a Tracker rear. Are you using spiders from a 8.8 or a 9"?
-
That is totally cool. I've always liked the looks of the 2ng gens better than the 1st gens. This last summer I could have bought an 03 Tracker with hard and soft tops and 100k miles for $5000. Instead I bought an 05 Wrangler Unlimited for more than twice that. Now I get to pay through the nose for gas. I wish I had stayed with a Zuk!
-
That is totally cool. I've always liked the looks of the 2ng gens better than the 1st gens. This last summer I could have bought an 03 Tracker with hard and soft tops and 100k miles for $5000. Instead I bought an 05 Wrangler Unlimited for more than twice that. Now I get to pay through the nose for gas. I wish I had stayed with a Zuk!
You can always come back to the 'Dark Side' >:D
-
However, I have 31 spline ford spiders mixed with a suzuki lock rite locker in a tracker rear being used as a front diff in my buggy. After all that I would think the XL7 issue should be fairly simple. Just gotta figure out how much crap needs to be machined ;)
I don't remember reading about running Ford spiders in a Tracker rear. Are you using spiders from a 8.8 or a 9"?
They are from a 9 inch. I never did write up anything on it. 37kicker and I were just diggin through a pile of parts one night and realized that a nine inch side gear had the same tooth count as a tracker. We were having a few beers at the time and our imaginations were working overtime. Next thing you know the grinder was in hand and the lathe was turning. :) We changed the pitch thickness and overall diameter of the face. Then turned the bearing size down and machined out the tracker carrier. There is a little more to it than that, but all in all it was just good times.
-
How necessary was the V6 swap? What kind of gas mileage did it get on the trip?
-
I can tell you, without the turbo, my truck on 33s with 5.83s
is a slug on the road, to have this as a road going truck and
not a trailer queen, you will want more power just to keep
from getting run over by slow moving semi trucks ;)
Wild
-
More Power! Always a good thing.
-
They are from a 9 inch. I never did write up anything on it. 37kicker and I were just diggin through a pile of parts one night and realized that a nine inch side gear had the same tooth count as a tracker. We were having a few beers at the time and our imaginations were working overtime. Next thing you know the grinder was in hand and the lathe was turning. :) We changed the pitch thickness and overall diameter of the face. Then turned the bearing size down and machined out the tracker carrier. There is a little more to it than that, but all in all it was just good times.
Great. Now I'm going to be looking at what it would take to use cut down Ford 9" axles in the rear...
-
They are from a 9 inch. I never did write up anything on it. 37kicker and I were just diggin through a pile of parts one night and realized that a nine inch side gear had the same tooth count as a tracker. We were having a few beers at the time and our imaginations were working overtime. Next thing you know the grinder was in hand and the lathe was turning. :) We changed the pitch thickness and overall diameter of the face. Then turned the bearing size down and machined out the tracker carrier. There is a little more to it than that, but all in all it was just good times.
Great. Now I'm going to be looking at what it would take to use cut down Ford 9" axles in the rear...
When you get to that point, why not just swap in a 9"? With the shaved pumpkin you would get close to the same clearance and have a 9" ring gear.
-
Great. Now I'm going to be looking at what it would take to use cut down Ford 9" axles in the rear...
When you get to that point, why not just swap in a 9"? With the shaved pumpkin you would get close to the same clearance and have a 9" ring gear.
True, but keep in mind an XL7 rear is nearly a 9 inch ring gear. If you swap to a ford 9 you have to buy brakes, gears, pinion flange, and make lots of brackets for links, shocks, coils ect.
-
This is where if we were kids sitting around looking at your new toy, I would be the one jumping up and down yelling , " now do mine, do mine!" ;D
-
This is where if we were kids sitting around looking at your new toy, I would be the one jumping up and down yelling , " now do mine, do mine!" ;D
I built this one with an automatic so I my kids would have an easier time driving it. Both of them have been driving it quite a bit. Eventually I will swap a 5 speed into it. I am not a fan of autos.
-
How necessary was the V6 swap? What kind of gas mileage did it get on the trip?
I dont know how necessary the swap was but I just wanted to not have to have the gas pedal to the floor everywhere I went. My old orange rig was always to the floor. Oddly both rigs fair about the same mileage. 18 with my regular (hard) driving and 21 driving nice. That being said the V6 is alot faster. I think that It would do a lot better if it had a manual trans. Im not a fan of this auto.
-
I averaged 15 to 17 MPG with the turbo, on 33s with 5.83 diff gears
on my trip to Moab when I drove there in the Sidekick, and I have
the old 3 speed auto trans.
It's not the trans it's the driver with the MPGs ;) that and redline all the time
Wild
-
How do you like the new BFG mud terrains? Mine is a daily driver and I'm just as concerned how they are on the road as off. Noise is probably the biggest issue for me that kept me with all terrains last time I bought tires.
-
How do you like the new BFG mud terrains? Mine is a daily driver and I'm just as concerned how they are on the road as off. Noise is probably the biggest issue for me that kept me with all terrains last time I bought tires.
You know, I got some new KM2 last year and I am AMAZED at how quiet they are. Way better then the old BFG MT, similar but better than the BFG AT, and better than the old Goodyear MTR. ...and they work good offroad too! Tire tech has come a long way in the last few years and I think these tires benefit from new developments and technology.
YMMV
-Eric
-
When you get to that point, why not just swap in a 9"? With the shaved pumpkin you would get close to the same clearance and have a 9" ring gear.
True, but keep in mind an XL7 rear is nearly a 9 inch ring gear. If you swap to a ford 9 you have to buy brakes, gears, pinion flange, and make lots of brackets for links, shocks, coils ect.
And it wouldn't be legal for the Zukiworld Challenge. You have to keep a Suzuki rear housing. :D
And we are a lot lighter. Those 9" axles are heavy buggers...
-
Just wonderin, how much stuff has to be moved or exended to do the frame chop. Mike Hagen would you be willing to give us a write up on what wires, lines, and other stuff you had to mess with. This sounds like a great way to get cheap lift but it sounds a little intimidating.
-
also, did you just cut and extend the steer shaft?
-
How do you like the new BFG mud terrains? Mine is a daily driver and I'm just as concerned how they are on the road as off. Noise is probably the biggest issue for me that kept me with all terrains last time I bought tires.
You know, I got some new KM2 last year and I am AMAZED at how quiet they are. Way better then the old BFG MT, similar but better than the BFG AT, and better than the old Goodyear MTR. ...and they work good offroad too! Tire tech has come a long way in the last few years and I think these tires benefit from new developments and technology.
YMMV
-Eric
Thats how I feel as well. These tires are by far the quietest mud terrain tire I have ever run by a wide margin. The pattern is nearly Identical to the BFG Krawlers I ran on the orange rig. I was very pleased with those as well. I had good luck with the goodyear MTRs as well but they were the loudest tire I have ever ran. Yes, I am including my radial swampers.
-
Just wonderin, how much stuff has to be moved or exended to do the frame chop. Mike Hagen would you be willing to give us a write up on what wires, lines, and other stuff you had to mess with. This sounds like a great way to get cheap lift but it sounds a little intimidating.
Really all that was done was relocate some brake/fuel line holders. I did not open any lines. There is no electrical. It should be a little intimidating. Before you take on a project like this you should be sure that you have the fab skills to succeed.
also, did you just cut and extend the steer shaft?
Ooops, I forgot about that! :-X Yes I did. I will post up a picture later tonight of where I cut.
-
Since your so kindly answering questions.....how about Driveshafts? Another 4 dr rear shaft?
-
That's good news on the BFG tires. Thanks for the info!
-
Since your so kindly answering questions.....how about Driveshafts? Another 4 dr rear shaft?
I welded a pipe up in the front to lengthen it. I wasnt worried about vibration since I dont use 4wd on the street. For the rear I had a shaft made to the correct length I needed. Ive got a pretty good hook up so it didnt cost much.
-
BTW I forgot to get the steering shaft pic. Sorry, but it will have to wait till sunday. I have to work a long shift tommorrow with the threat of snow coming.
-
I've been gone for a while, but do come back ever so often to catch up, just never read into the overall Suzuki4x4 forum too deep.
Mike, what you did with RockStar, I just loved the whole build of it. That gave me ideas for my XL7. Currently, its a high school commuter for my daughter. I would like to do the something similar once I get it back.
Now, you've gone and done it on the 3rd generation. Your time schedule you keep in builds surprises me. With all these mods, you tend to put a cap on relaxation and enjoyment of the build and complete with a stressful end time. Do you think your Mr. Foose?
Looks real nice and hope to see some wheeling pics in the next few months.
-
I've been gone for a while, but do come back ever so often to catch up, just never read into the overall Suzuki4x4 forum too deep.
Mike, what you did with RockStar, I just loved the whole build of it. That gave me ideas for my XL7. Currently, its a high school commuter for my daughter. I would like to do the something similar once I get it back.
Now, you've gone and done it on the 3rd generation. Your time schedule you keep in builds surprises me. With all these mods, you tend to put a cap on relaxation and enjoyment of the build and complete with a stressful end time. Do you think your Mr. Foose?
Looks real nice and hope to see some wheeling pics in the next few months.
Foose? I wish. He has a whole team LOL! In all honesty I couldnt do it any other way. I have a really busy life. The only way I get anything done is to make time. Put everything I can on hold and go to work on whatever it is. I pretty much just went to work at my job, slept just enough to get by, and worked on this thing. While it was a lot of work I cant say that it wasnt enjoyable. I love watching a project come togather. Actually I love the beginning of project vehicles as well. The only part that kinda sucks is the middle when the end seems so far away and Im getting burned out.Seeing the look on the kids faces helped keep my eyes on the prize which kept me going. I hope to get many years of enjoyment out of this vehicle so it was worth the extra effort.
BTW with the snow we have gotten here lately Ive been putting in a ton of hours at work lately and just forgot about the picture of the steering shaft. I will get that posted on tuesday.
-
Mike,
Congrats, great build. Appreciate the photos and description. I just picked up a mint 2002 ZR2- Yellow in color. My question for you is the 5.12 gears you installed were from what unit? I just tried to order a mini spool from Trailtough and they told me the one they sell wont fit my 4.62 diff. You mention the XL-7 axle, is this comparable to the stock ZR-2 , 3rd member swappable? What parts are you using? Year ? Spline count ? blah blah ?
Also are you using the stock Rack and Pinion or did you convert to steering box...?
Thank you very much for your time !
Marc
-
Mike,
Congrats, great build. Appreciate the photos and description. I just picked up a mint 2002 ZR2- Yellow in color. My question for you is the 5.12 gears you installed were from what unit? I just tried to order a mini spool from Trailtough and they told me the one they sell wont fit my 4.62 diff. You mention the XL-7 axle, is this comparable to the stock ZR-2 , 2rd member swappable? What parts are you using? Year ? Spline count ? blah blah ?
Also are you using the stock Rack and Pinion or did you convert to steering box...?
Thank you very much for your time !
Marc
I believe that the Zr2 rear came with a 7.5 inch ring gear and the XL7 has a ring gear close to 9 inch. The 7.5 diffs are 26 spline and the XL7 has 28 spline rear axles. The 5.12 gears for the front were out of a early 90s tracker. I put those into a carrier from a 2001 grand vitara 5 speed which is steel. The 2003 automatic XL7 came with a 5.12 gears. I am using the stock rack and pinion.
-
also, did you just cut and extend the steer shaft?
Yes I know I had an oil leak. :P I put a timming chain tensioner in it and I had a little weep out of the left valve cover. I clearly didnt clean it up as well as I thought I did. Anyway, I cut the lower shaft between the isolator and the u joint at the rack and pinion. This had the least amount of angle on the Ujoints.
-
I was out wheeling yesterday and I had to post this pic. Running a little Wisconsin winter camo.
-
How is this thing going.
Is it still holding up.
Any thing break yet
Have u solved the rear locker problem yet.
-
Hey mike, That looks great. As usual, you took to your original theory,( just use your imagination ). I done mine 4 years ago following project rockstar and never looked back. These rigs are unbelievable, light, nimble, easy to work on and now there's a bunch more aftermarket. Thanks for takin the time to do a write-up, it always amazes me.
-
I did not know about this build until I saw the newsletter about the Zukfest. Really well done build! Looks like it did the Moab trip well.
I have been dreaming about a V6 swap in my 2001. Can you elaborate more about that effort?
(http://img571.imageshack.us/img571/5075/img9672p.jpg)
-
I'm sure you would need the complete engine, trans assy and wiring harness from the donor vehicle. Should be a pretty much bolt in affair though. I would make sure I got a Suzuki Vitara (not Grand) V6 or the Chevy Tracker V6 as both were made in Canada at the same place where your two door was built. This would guarantee the frame dims would be the same. I know that the GV and XL7 had a wider track and possibly a wider frame in some sections.